Published by the DECEMBER 2008 WaterJet Technology Association for the benefit of its members

906 Olive Street, Suite 1200 l St. Louis, MO 63101-1448, USA l Telephone: (314)241-1445, Fax: (314)241-1449 -Waterjet Machining Of Composites

AWJ-drilled holes in a carbon fiber composite panel. See article by Mohamed Hashish, Ph.D., on page 2

2009 American WJTA Conference and Expo, Details inside August 18-20, 2009 l Houston, Texas, USA Abrasive-Waterjet Machining Of Composites, from page 1 By Mohamed Hashish, Ph.D., Member – WJTA, Flow International Corporation, Kent, Washington 98032

Abstract jet engine and air frame components. • Keel Beam, Centre Wing Box, In jet engine for example, the engine Belly Fairing The use of carbon fiber composites cold section will incorporate OMCs, is significantly increasing as a MMCs, and intermetallics. OMC The following are example aircraft structural material for commercial components may include fan frames, and corresponding AWJ-machined airframes. This material represents fan blades, inlet and outlet guide components: 50% by weight for the new Boeing vanes, stator vanes, cases, and control 787 and Airbus 350XWB frames. housings. Graphite-PMR-15 structural • Boeing 787 - center wing box, The Abrasive-Waterjet (AWJ) has parts are used on such engines as wing skins, spars, stringers, fixed been the of choice for trimming GE F110 and F404, and PW-1120 leading edge, vertical stabilizer, and shapecutting this material due to and 1130. Hot sections, such as 777 – horizontal stabilizer, 747 - many technical, environmental, and combustors and turbine exhaust, titanium landing gear components economical reasons. The AWJ cuts will require the high-temperature - see Figure 1 below are of acceptable surface finish and capabilities of some intermetallics, • Airbus 350XWB – wing spars of high integrity. The cutting rates single-crystal superalloys, CMCs, or • Bell Helicopter V-22 Osprey - are faster than conventional routing. carbon/carbon composites. wing skins, stiff rotors Significant advances have been made • Raytheon Premier I – The fuselage. in the hardware, software, and the The use of OMCs, especially AWJ process reliability, flexibility, carbon-fiber based composites for The most common AWJ-cut carbon and productivity placing the AWJ aerostructures, have been initially used fiber composite parts in an air frame process as a mainstream tool for on military airframes. Now carbon are found in: airframe manufacturers and their fiber composites are used extensively subcontractors. on commercial aircraft. Example parts Most revolutionary in the use of are: composites on commercial liners is the Boeing 787 which will contain 1. Introduction • Wing: Covers, Spars, Leading 50% composite structure by weight Edges, Flaps and 90% by volume and the Airbus The use of advanced materials such • Fuselage: Panels, Stringers, A350XWB with similar composite as composites has been escalating Frames, Clips, Doors usage. In comparison, the 777, which rapidly over the past three decades, • Tail: VTP & HTP Covers, Rudder, especially in the aerospace industry, and Flaps (continued on page 12) coincident with the introduction of AWJ technology to the marketplace in the 1980s. In fact, the use of waterjet technology in aerospace applications has a significant impact on its advance in meeting reliability, flexibility, and productivity demands. This article briefly discusses the AWJ hardware, software, and routinely used machining processes such as trimming and for carbon fiber composites.

1.1 Composite Systems

Composites used in the aircraft industry could be organic, metal, and ceramic matrix composites (OMCs, Figure 1: 777 Tail Fin Composite Structures MMCs, and CMCs). These are used in Page 2 WJTA on the web: www.wjta.org December 2008

Nominations Open For WJTA Board of Directors

ominations for the WaterJet Technology Association N (WJTA) Board of Directors are now open,” says WJTA Nominations/Elections Procedures Secretary Hugh B. Miller, Ph.D. “The duties of the directors are truly challenging and rewarding.” In accordance with the bylaws of the WaterJet Technology Association, nominations and elections to the The terms of office of Greg Galecki, Ph.D., Mohamed Board of Directors include the following procedures: Hashish, Ph.D., Hugh B. Miller, Ph.D., Bill McClister, George  At least two calls for nominations to the board of A. Savanick, Ph.D., and B.T. Steadman will expire in August directors will be published in the Jet News. The 2009. Therefore, nominations are sought for six (6) board first call for nominations appears in this issue. members, each to serve a four-year term of office beginning Nominations will be accepted through March August 17, 2009. 31, 2009.  An official ballot listing the eligible nominees and The WJTA bylaws provide that no more than one of the a brief biographical sketch for each individual will elected board members may be from the same company then be forwarded by mail to all eligible voting or organization. Therefore, board members may not be members of the Association on May 28, 2009. Signed and executed ballots must be mailed to nominated from the same company or organization already the Association’s office for tallying by June 25, represented on the board by individuals whose terms expire 2009. in 2011, including DeBusk Industrial Services Company (Pat DeBusk), High Pressure Equipment Company (Larry Loper),  The names of newly elected board members will NLB Corporation (Forrest A. Shook), StoneAge, Inc. (John be announced in the Jet News and on the WJTA Wolgamott), Environmental Solutions Group/Federal Signal web site. (Bill Gaff), and Polyflex Business Unit/Parker Hannifin Only WJTA members in good standing (2008 membership Corporation (Paul Webster). dues paid) may submit a nomination(s). A nominee who has not paid his/her dues by March 31, 2009, shall be According to the WJTA bylaws, any WJTA member in declared ineligible to run for office in the 2009 election. good standing (2008 membership dues paid) may submit a nomination(s). A nominee who has not paid his/her dues by March 31, Nomination Form 2009, shall be declared ineligible to Name of Nominee ______run for office in the 2009 election. The deadline for making nominations is Title ______March 31, 2009. Your nomination(s) Address ______should reach the WJTA office no later City______State ______than March 31, 2009. Country ______Postal Code ______Telephone______Fax ______To submit a nomination(s), complete the Nomination Form and Email ______return, along with biographical Attach biographical information with a brief statement information and a brief statement of of your nominee’s mission and vision for WJTA. your nominee’s mission and vision for WJTA, to: Name of Nominator ______Title ______WJTA Administrative Office Address ______906 Olive Street, Suite 1200 City______State ______Saint Louis, MO 63101-1448 Country ______Postal Code ______Phone: (314) 241-1445 Fax: (314) 241-1449 Telephone______Fax ______Email ______

Remember, nominations must be Return completed Nomination Form and supporting information to: received no later than March 31, 2009. WJTA Administrative Office, 906 Olive Street, Suite 1200, Saint Louis, MO 63101-1448

Page 4 WJTA on the web: www.wjta.org December 2008

G.O. H2O Attributes Continued Growth to Diverse Markets Edmonton Waterjet Shop Experiences Nine Straight Years of Growth

hen Garnett Gerke opened his Gerke credits his former W Edmonton, Alberta, waterjet business partner for coming shop, G.O. H2O, more than ten years up with the idea of opening ago, he deliberately decided to target a waterjet shop. His partner diverse markets rather than hinge his got the idea while working fate on a niche industry. on a road construction crew in northern Alberta. The This approach has served G.O. H2O crew ran into challenges well. The company has grown every trying to through rock year for the past nine years, and even so he went online to research added a second waterjet table last year the idea of cutting material to keep up with demand. with something more innovative and efficient than “We attribute our growth to coring methods. After some Alberta’s strong oil and gas-based research, he determined that Garnett Gerke of G.O. H2O, Edmonton, Alberta. economy, but also to the fact that waterjet was the wave of the we market to other areas such as future in terms of cutting, of the world,” yet the city only had architectural, glass, flooring, metal and also found that Edmonton was one waterjet shop at that time. fabricating and a small amount in considered the “machine shop capitol plastics,” Gerke noted. (continued on page 7)

Page 6 WJTA on the web: www.wjta.org December 2008 Edmonton Waterjet Shop Experiences Nine Straight Years Of Growth, from page 6

Gerke’s 12 years in the trades as a “When we did have downtime, Jet went in and shipped the part out. We cabinetmaker coupled with four years Edge’s customer service was amazing, were back up and running for the of marketing experience came in even on holidays,” he added. “On weekend.” handy as the men built their business. one of the rare times our system went They decided to focus primarily on down, it went down over the U.S. After more than ten years of positive waterjet cutting rather than machining Thanksgiving holiday, which is not experiences, Gerke said he would since the area was saturated with a holiday for us. I called Jet Edge’s machine shops. emergency service contact, and they (continued on page 20)

When they bought their first waterjet table, they chose a 4x12-foot High Rail Gantry manufactured by Jet Edge, Inc. of St. Michael, Minnesota. They equipped the table with two cutting heads and powered it with a 100hp, 55,000 psi (4,100 bar) Jet Edge 55-100 intensifier pump with dual intensifiers.

“We liked the idea that Jet Edge was a privately owned company versus a publicly traded company,” Gerke said. “We also liked their reputation of quality.”

G.O. H2O had racked up nearly 35,000 hours on its first system when Gerke and his new business partner, Don Torok, decided to buy a second system.

For the second system, the company went with a 6x12-foot Jet Edge High Rail Gantry so they could accommodate larger sheet sizes. They equipped this system with two cutting heads and a 55-100 Jet Edge intensifier pump. Both waterjet systems are equipped with overhead cranes, and Gerke noted that the tables are very easy to load by crane or forklift.

“When it was time to buy the second machine, it was very tempting to look at the other manufacturers, and we did, but how can you argue with 35,000 hours and very little downtime,” Gerke said, noting that on his original ten-year-old pump, he has only had to replace one of the intensifiers. The electric motor and one intensifier are still original.

December 2008 WJTA on the web: www.wjta.org Page 7 Flow Opens New Cutting Hollow Structures

Czech Republic any applications Sales and Customer M in waterjet cutting are involved Service Center with hollow structures. The hollow space tends to disperse the jet and low International Corporation affects the cut below. has announced the opening of F Louis & Von Rad* did a new sales and customer service an experimental study center in the Czech Republic. The on this phenomenon. new center, located in Brno, Czech Here is a review of their Republic, will serve customers in findings. central and Eastern European markets, including Croatia, Slovenia, Hungary, Their experimental Romania, Poland, Czech Republic, setup to simulate a Slovakia, Russia, Belarus, and the hollow structure is Ukraine. The center was opened in illustrated in the top response to the growth of Flow’s figure. Cutting tests European customer base in those were done on aluminum countries and the future growth with a 1-mm abrasive opportunities in these countries. water suspension jet at 70 MPa of pressure and “As a result of the increased demand 2 kg/min of 80 mesh for waterjet cutting technology garnet. The parameters worldwide and Flow’s growing were chosen so that the European customer base, we seized sample below the gap the opportunity to open a sales and was not cut through in service center to best serve our Eastern order to preserve the European customers,” said Charley evidences of remaining Brown, CEO, Flow International. jet potential. The gap “The new center will complement our was filled with either European headquarters in Bretten, air or water to study the Germany so Flow can continue to impact of medium. The deliver the highest possible service to results were plotted in our growing European customer base.” the other two figures. For more information, visit www. The reduction of flowcorp.com. the kerf depth and the increase of the to the kerf-width-vs-gap-size relation kerf width on the sample were (i.e., a thicker upper plate resulted in proportional to the size of gap. a wider kerf). The explanation was Compared to air, water made that the upper plate acted as a “bad” the kerf shallower and narrower nozzle. because the outer layer of the jet th WJTA 25 lost energy to the surrounding *Louis, H. & Ch Von Rad (2000), “Cutting Anniversary water. It was also found that the of hollow structures with abrasive water thickness of the upper plate had suspension jets,” in Proceedings of the 1983-2008 15th International Conference on Jetting a small impact to the kerf-depth- Technology, Ronneby, Sweden, September vs- gap-size relation (i.e., a thicker 6-8, pp59-67. upper plate resulted in a shallower Reprinted by permission from Quality kerf), but a relatively large impact Waterjet Newsletter, October 7, 2008. Page 8 WJTA on the web: www.wjta.org December 2008 Personnel Appointments

• Jet Edge, Inc., has announced the has traveled extensively throughout • SPIR STAR Ltd. appointed a appointment of Eric Magnuson as the world and has established new sales representative, Willie its new North Central regional sales OEMs, dealers, and distributors in Whittington, in September. manager. Magnuson is responsible approximately 35 countries on six Whittington has over five years for sales of Jet Edge waterjet continents. In 1997, the governor of of inside sales experience. His systems in Minnesota, North and Minnesota recognized Anderson’s primary responsibilities will be to South Dakota, efforts and the company that he assist in the development of SPIR Wyoming, worked for at the time with the STAR’s sales strategies and to help Nebraska, “Exporter of the Year Award.” maximize customer satisfaction and Western Iowa, Anderson is based in St. Michael, performance. For more information, Northern Minnesota, and can be contacted at visit www.spirstar.com or call Wisconsin and (763)497-8718 or [email protected] (281)664-7800. Manitoba. He brings to Jet Edge more than IMPORTANT NOTICE REGARDING SPAM 10 years of Eric Magnuson experience in Email addresses and other member contact information published in the WJTA Membership capital equipment sales. Magnuson Directory is meant to encourage helpful, informative communication between members. The information is not provided to circulate spam or junk mail. has a mechanical engineering degree The WJTA leadership requests that members respect the contact information of fellow mem- from the University of Minnesota. bers and not use that information for the dissemination of spam or junk email. Membership He is based in St. Michael, information is not meant to be circulated beyond the WJTA membership. Minnesota, and can be contacted at phone: (612)963-0933 or email: [email protected].

• Jet Edge, Inc., has also announced the appointment of David J. Anderson as its new international sales manager. Anderson is responsible for export sales of Jet Edge waterjet UHP pumps and systems. He brings to Jet Edge 15 years of experience in sales David J. Anderson management, marketing, training and customer service in international and domestic business sales. Recently Anderson was an advisor to U.S. and foreign businesses regarding risk management, sales process, and marketing management. He has previous experience in sales and marketing management with specialized water pump capital equipment manufacturers. Anderson

December 2008 WJTA on the web: www.wjta.org Page 9 Select FS Solutions Centers Now Offer StoneAge Service And Repairs

o better serve industrial cleaning “There is physics behind how you shipping costs and time for everyone. T contractors, plant customers and make a water-spin tool and how you We want our back in the other industry professionals, Federal jet it,” said Bill Shires, vice president operator’s hands with the least amount Signal Environmental Solutions of sales and marketing for StoneAge. of downtime as possible.” Group has announced that the FS “The technical sales specialists at FS Solutions centers in Toledo, Ohio Solutions have been fully trained by Since 1979, StoneAge, Inc., and Long Beach, California, are StoneAge engineers and are uniquely Durango, Colorado, has been a leading authorized repair and service centers suited to answer customer questions provider of high-pressure waterblast for StoneAge brand waterblasting about which StoneAge tools to use to cleaning solutions. StoneAge products and sewer cleaning tools, parts and remove specific materials in specific are used in a variety of industrial accessories. applications. FS Solutions also has cleaning applications, including power the necessary machining expertise and plants, refineries, pharmaceutical “At FS Solutions, we are proud to tooling capabilities to repair our high companies and shipyards. offer the kind of dependable products, tolerance tool components.” parts and services – like the StoneAge For more information about line of waterblast tools – that our StoneAge products include the StoneAge products and services, customers need to get the job done,” Hurricane® 3D vessel and tank call (866)795-1586, or visit www. said Bryce Mulligan, rental manager cleaning tool, the Barracuda® 20,000 stoneagetools.com. for FS Solutions. “We are also proud and 40,000 psi rotary nozzles and that the technicians at our Toledo and Warthog® sewer cleaning tools. “We For more information about products Long Beach centers have the training are committed to building great and services available from the FS and expertise to repair and rebuild tools,” Shires said. “The location Solutions centers or to find the nearest StoneAge products locally, rather than of the StoneAge factory is far from location, call (800)627-3171, ext. 298, requiring customers to rely solely our customers’ job sites. Having or visit www.federalsignal.com. on the StoneAge service location in authorized repair locations minimizes Durango, Colorado.”

Page 10 WJTA on the web: www.wjta.org December 2008

2009 American WJTA Conference and Expo

Tuesday-Thursday, August 18-20, 2009 Marriott Houston Westchase, 2900 Briarpark Drive, Houston, Texas 77042

• Live, Onsite Demonstrations of a variety of waterjet applications (including cleaning, /coating removal, concrete preparation and testing of the effectiveness of safety equipment) and industrial vacuum/air moving operations.

• Waterjet Expo featuring displays of waterjetting equipment, systems and supplies and industrial vacuum/air moving vehicles.

• Waterjet Boot Camp—Industry experts offer information and suggestions on ways to help contractors buy smart, improve efficiency and generate profitable new business.

• Pre-Conference Workshops s Waterjet Technology - Basics and Beyond s Vacuum Equipment Safety Seminar

• Emerging Technology, New Applications—Hear some of the world’s foremost engineers and researchers share new developments in applications, mechanics, equipment, and procedures.

The WJTA Conference and Expo is unique in that the program is dedicated to high pressure waterjet technology and related industries. If you are involved in high pressure waterjetting for cleaning, surface preparation, industrial vacuuming/ air moving for industrial cleanup/recovery, waterblasting or cutting, or if you are interested in finding out more about the industry, theWJTA Conference and Expo is an ideal resource for information and an excellent meeting for networking with other professionals in the field.

Hotel Reservations at the Marriott Houston Westchase. The Marriott Houston Westchase, 2900 Briarpark Drive, Houston, Texas 77042, is the central location for the WJTA Conference and Expo activities. The Marriott is a smoke-free facility. For reservations, call toll-free 800-452-5110 or contact the Marriott directly at 713-978-7400. Be sure to identify yourself as attending the WaterJet Technology Association Conference to receive the special group rates of $149 single/double occupancy. August 2, 2009, is the deadline for guaranteed room availability. Reservations received after August 2, 2009, will be confirmed on a space available basis. Rooms may still be available after August 2, but not necessarily at the rates listed above.

Visit www.wjta.org for Conference information or contact: WJTA, 906 Olive Street, Suite 1200, St. Louis, MO 63101-1448 Phone: 314-241-1445, Fax: 314-241-1449, Email: [email protected]

December 2008 WJTA on the web: www.wjta.org Page 11 Abrasive-Waterjet Machining Of Composites, from page 2 entered service just over ten years and slowdown of ago, contains only 10% composite production cycles. structure by weight. The military’s Frequent tool change new F-35 Lightning II (JSF) expected is required when to enter service in 2010 will have just using routers or below 40% composite structure by due to the weight as Titanium Graphite (TiGr) abrasive nature laminates will be used. The F-22 of the composite. Raptor, which entered service in 2003, Environmentally, has approximately 25% composite solid tools generate structures by weight. Figure 1 above dust and carbon shows the 777 tail fin with shaded powder which can areas being carbon fiber composite wreak havoc on Figure 2: Materials Used in the Boeing 787 Aircraft while Figure 2 shows the composite electrical systems and parts on the 787. personnel. several advantages over conventional machining methods. Among these Typical problems that have been The above mentioned growing use advantages are: encountered when machining­ carbon of composite materials on primary fiber composites with conventional aircraft structures requires technology • No distortion due to limited solid tools are matrix cracking, offering lower manufacturing and jet forces and its nature of fiber pullout, inter-laminar voids, tooling costs, and the reduced potential micromachining action delamination, and resin melting. for product defects. For 2D and 3D • No heat affected zones This leaves frayed or delaminated cutting and machining of composite • Higher cutting speeds than routers edges which require costly rework structures, AWJ technology offers (continued on page 13)

WATERWATER JETTINGJETTING SYSTEMSSYSTEMS

281-448-5800 • FAX: 281-448-7500 1-800-231-36281-800-231-3628 www.waterjetting.com • [email protected]

Page 12 WJTA on the web: www.wjta.org December 2008 Abrasive-Waterjet Machining Of Composites, from page 12 • Reduced fixturing and tooling • No delamination • No subsequent processes are needed. • No splintering or fraying edges • Process automation and multi-operations are possible • No dust

In the following sections we describe some advances in composite machining.

2. AWJ Technology Advances for Composites Machining

There have been many advances in composites machining with AWJ for air frames that can be grouped into two basic categories. These are machinery (hardware) process, and Figure 4: Hybrid Waterjet System software advances. The following are descriptions of some (Waterjet on the left, outer on the right) of these advances.

2.1 Hardware:

2.1.1 Cutting Heads

The use of vacuum assist in AWJ cutting heads, see Figure 3, has been critical for successful shapecutting of composites. An external vacuum source is used to draw into the cutting head before starting the waterjet. This insures an waterjet instantaneous Wrist action of the AWJ upon firing Wrist the waterjet and Figure 5: AWJ and Mechanical End Effectors impacting the Figure 3: AWJ Cutting Head with material. It has Vacuum Assist. One port is for abrasive such as the one shown in Figure 5. Please note that a been shown that feed and the other for attaching vacuum small catcher is provided on a 6th axis for catching the exit delimitation does device. jet and directing the waste outside of the wrist area to the not occur when collection tank. The router, see Figure 5, is used to drill piercing composites using this approach. The vacuum and counter sink the required holes or trim some critical assist is particularly important when lower pressures are areas not easy to address with the AWJ. This system used as often is the case when piercing composites. In this provides significant advantage in minimizing set-up time. case, the waterjet venturi effect is not sufficient to draw Machines range in size from 10 ft to 150 ft in length with abrasives reliably into the cutting head and thus vacuum width up to 50 ft. Probing and linear scales are used for assist enhances the reliability of the AWJ process. obtaining the required accuracy.

2.1.2 Hybrid Waterjet System 2.1.3 Flexible Fixturing

In order to trim and rout composites, both waterjets and Flexible fixturing is a key component in AWJ machining solid tool routers have been incorporated on special hybrid cells due to the wide variety of shapes and contours of systems as shown in Figure 4. In these systems, two 5-axis airframe parts. FLOW has developed versatile fixtures masts are used: one for the AWJ and another for the router. consisting of a number of linear actuators with vacuum The AWJ is used to trim the part using an end effector (continued on page 14) December 2008 WJTA on the web: www.wjta.org Page 13 Abrasive-Waterjet Machining Of Composites, from page 13 cups as well as hard location surfaces used for airframe are and points for accurately locating trimming, shapecutting, the part and rigidly holding it during and drilling. Trimming cutting. The must also is typically performed accommodate the catcher and be on the edges while specific to the waterjet nature as a shapecutting is long effective beam after penetrating performed on the the material. Figure 6 shows a fixture interior surfaces to example for holding a wide range produce openings of curved parts as may be used in such as access holes or fuselage sections. windows.

2.2 Software 2.3.1 Trimming and Shapecutting Most airframe parts are designed using CATIA solid modeling software. In Significant work has order to develop a CNC program to been done on the use of trim and drill parts, a post processor waterjets and abrasive- program is needed to translate the waterjets for composite drawing such that the machine parts trimming. controller can execute it. This post This trimming is processor also includes information required as parts are about the process such as cutting typically oversized speed, tool diameter, etc. This is due to the composite Figure 6: Example Fixture for Holding Curved a most critical element of the AWJ manufacturing process. Parts machining system as most parts A wide plateau of are complex 3-D shaped. Flow parameters has been International and CINET Systems found acceptable for developed FlowTrim: CAD (Data cutting wide range Import, Part Design, Fixtures, Run-off of thicknesses - (0.1 material), and CAM (Programming, inch to 3-inch) simulation, tool path modification, …) sections of graphite as an integrated post processor using epoxy. The cut integrated cutting technology models surfaces of better and data tables. Figure 7 shows an than 400 micro example screen with the end effector inches (as typically and catcher displayed. specified by Boeing) are achieved at 2.3 Waterjet Processes relatively high Figure 7: FlowTRIM® Software Screen by CINET productivity levels. showing AWJ trimming end effector The most common waterjet processes For example, a (continued on page 15)

Safety Committee Solicits Comments On Improvements To Recommended Practices he WJTA Safety Committee hereby solicits comments regarding improvements to the publication, Recommended T Practices for the Use of Manually Operated High Pressure Waterjetting Equipment. While Recommended Practices is reviewed periodically at the biennial conferences of the WaterJet Technology Association, your comments and sugges- tions for improving the publication are invited and welcome anytime. Please address your comments and suggestions to: Safety Committee, c/o WJTA, 906 Olive Street, Suite 1200, St. Louis, MO 63101-1448, phone: (314)241-1445, fax: (314)241-1449, email: [email protected], web site: www.wjta.org. Page 14 WJTA on the web: www.wjta.org December 2008 Abrasive-Waterjet Machining Of Composites, from page 14 cutting speed of 20 inch/min can be used Figure 8. Composite Trimming and Shapecutting Examples to trim a 0.35-inch thick carbon fiber using a 0.010 inch AWJ at 55 ksi.

Some edges may be trimmed at angles, and when cutting around curves and complex contours, the effective depth of jet cutting varies and thus waterjet kinematics parameters such as speed and angles need to be carefully programmed to maintain uniform edge quality. Trimming I-Beam (stringer) a. Composite Stringer b. Required Trimming of composites requires special tooling stringer flanges and ends such as catchers and cutting heads. Figure 8-a shows a cross section of a stringer with the top flange trimmed at 90 degrees with an AWJ. The bottom flanges show the condition of the edge before trimming. Figure 8-b shows a trimming overview example for the 787 aircraft stringers. The top and bottom flanges are shaped trimmed with the ends trimmed to the center rib or very close to it. Also, the bottom flange needs to be beveled at about 45 degrees. Some access holes are also drilled in the rib. These stringers, d. AWJ trimming and cutting of especially the ones used in the wings are c. Access Hole drilling complex 3-D composite wing part relatively long, over 130-ft, and thus they require at the root of a wing special machinery to handle them during cutting. box stringer Shapecutting requires the piercing of a starting (continued on page 16) hole. Some systems use a mechanical drill to pre-drill the starting holes but most commonly now, AWJ is used to drill

Guzzler Reintroduces Predator™ Liquid Vacuum Tanker

uzzler Manufacturing has The liquid vacuum tanker vacuum pump capable of suction G announced the reintroduction of combines high vacuum and pressure pressures up to 27-29 inches Hg; the Predator™ liquid vacuum tanker offloading designed to deliver reliable maximum airflow of more than 400 designed for handling bulk liquids, performance in the most demanding CFM and more than 300 CFM at 18 sludge and semi-solid waste in inches Hg. Alternate pump sizes industrial applications. are also available.

“With the relaunch of the The Predator’s single Predator, a full line of industrial compartment tank is constructed vacuum trucks is now available with carbon steel and is rated from Guzzler Manufacturing, for continuous maximum complete with the parts, service, vacuum operation and 15 psi training and industry expertise working pressure. Built in you expect from the Guzzler accordance with Section VIII of brand,” said Tim Lee, product applications. The 3,000 gallon payload manager for Guzzler. capacity tanker features a standard (continued on page 23) December 2008 WJTA on the web: www.wjta.org Page 15 Abrasive-Waterjet Machining Of Composites, from page 15 these holes as part of the shapecutting sequence. In this case, vacuum assist nozzles are used to mitigate risks of delamination. Figure 8-c shows holes drilled at the root of a stringer rib. In order to cut near the bottom flange, a special minimal-size AWJ nozzle is used. The example trimming and shapecutting shown in Figure 8-d is quite complex due to the 3-D nature of the trimming in different planes. The design of a holding fixture in this Figure 9: AWJ-Cuts in Thick example is of critical importance. Composite Section

While the majority of trimming applications addresses relatively thin structures as shown in Figure Figure 12. sections (less than 0.75 inch), there 11. Cutting this class of materials are several thick section (up to 3-inch) introduces additional challenge as the 2.3.2 Drilling (Piercing) cutting applications near the wing- cutting path is not continuous. A cut at to-fuselage joining areas. Figure 9 the bottom of a honeycomb structure Delamination is the main mode of shows example cuts in thick composite appears as a series of punched failure when drilling materials such sections which were found to be faster holes. Cutting at a lead angle (a few than a mechanical tool by an order of degrees) has been found effective for (continued on page 17) magnitude using much less demanding minimizing this effect as shown in fixtures and heavy equipment.

The end trimming of composite stringers (I-beams) is another application that requires careful 5-axis manipulation strategy as not to cause the exit jet damage the opposite sides of the stringer. Figure 10 shows a trimmed section from the end of a stringer. A rate of 1 inch/min can be used to cut through a 3-inch thick section producing an acceptable 400-micro-inch surface finish.

A most challenging cutting application is the cutting of composite honeycomb

Figure 10: Stringer end cut off

Page 16 WJTA on the web: www.wjta.org December 2008 Federal Signal To Open Sixth FS Solutions Center In Gonzales, Louisiana

ederal Signal Environmental To help customers in Louisiana looking for faster, more cost-effective F Solutions Group opened its sixth and the Gulf Coast area with their ways to perform cleaning operations FS Solutions center in Gonzales, waterblast rental needs, the Gonzales or a business that can benefit from Louisiana on November 10, 2008. center is staffed by knowledgeable application expertise, equipment The new center, located at 3111 employees with significant evaluations or training, we’re S. Darla Avenue, will stock high waterblasting experience. A customer providing solutions.” performance parts and accessories for looking for an extra waterblaster for Federal Signal’s Jetstream brand of a short-term or seasonal contract can With nearly 100 years of collective waterblasters, as well as other makes choose from a full line of Jetstream experience in industrial vacuum and models of waterblasters. The units at the new Gonzales center – loading, sewer and catch basin FS Solutions center will also offer and FS Solutions will deliver the unit cleaning, vacuum excavation and customers the opportunity to rent or directly to the jobsite. Additional industrial high-pressure waterblasting, to own equipment and will sell used FS Solutions centers are located in FS Solutions offers unsurpassed waterblasters. Birmingham, Alabama; Long Beach, expertise and a unique breadth of California; Houston, Texas; Toledo, product lines and trusted brands to “FS Solutions centers – like the Ohio; and Streator, Illinois. meet the needs of industrial cleaning new Gonzales location – provide contractors and other industry the repairs, rentals, used equipment, All FS Solutions locations provide professionals. parts and accessories and training our access to factory-trained, certified customers need to run their equipment technicians and genuine OEM parts. For more information about products more profitably,” said Bryce Mulligan, “FS Solutions customers look to and services available from the FS rental manager for FS Solutions. “For our sales staff and service training Solutions centers or to find the nearest customers interested in safety and technicians for recommendations and location, call (800)627-3171, ext. 298, improved productivity, the Gonzales solutions to the unique challenges of or visit www.fssolutionsgroup.com. FS Solutions center will offer their particular applications,” Mulligan waterblast safety training.” said. “Whether it’s a contractor

Abrasive-Waterjet Machining of Composites, from page 16

Figure 11: Examples of Honeycomb Structures

Figure 12: Bottom Surface of 25-mm-thick Honeycomb Cut with an AWJ With and Without a Lead Angle (9°)

(continued on page 18)

December 2008 WJTA on the web: www.wjta.org Page 17 Abrasive-Waterjet Machining Of Composites, from page 17 as graphite epoxy with waterjets. This emerge using turned OMC problem is resolved when vacuum parts. While many composite assist and proper parameters are used. geometries have been turned, Thousands of holes have been drilled this application will not be in carbon fiber composites without any discussed in this article. adverse effects. With proper process timing, holes can be drilled rapidly. 2.3.3.2 While not as fast as laser, the holes are typically of high integrity and good The AWJ milling process is surface finish. The AWJ process has conducted by traversing the been successfully investigated for jets many passes close to each rapid drilling (piercing) of holes in other across the workpiece composites. For example, the picture surface. The multiple passes Figure 14: AWJ-Milled Bosses (5 mm in shown in Figure 13 illustrated the of overlapping kerfs are used diameter) in Gamma Titanium Aluminide drilling of 0.40 inch holes in a 0.040- to achieve controlled depth. inch thick composite material. The The milling of isogrid shapes drilling time in graphite epoxy (Figure 14) was about 0.9 was conducted to demonstrate seconds hole the degree to which the depth to hole. of milling can be controlled. This approach involved the The pierced use of steel masks. It was hole size can found that depth control can be controlled Figure 13: AWJ- be accomplished to 0.001 inch by selecting drilled holes in a accuracy. The material can the process carbon fiber composite be milled ply by ply if needed parameters panel (cover photo) suggesting its potential for and the dwell repair applications time. The larger the dwell time, the larger the final hole size at the exit. In the repair application, Figure 15: AWJ-Milled Scarf Joint in Accurate control over the dwell time is damaged material is first Graphite Epoxy needed to control the hole size within removed and then patched to certain tolerance limits. Another the original geometry. The interesting observation is that the flexibility of AWJ cutting in a wide drilling time is improved by reducing range of materials and shapes makes in the AWJ process combined with the water flow rate and increasing the it suitable for the repair of composite advances in machinery and software abrasive flow rate into the hole. structures. Alternatively, the AWJ has made this technology acceptable could be used for milling off the for the aircraft industry. Today, all 2.3.3 Emerging Applications damaged section or preparing the airframe manufacturers use AWJ for patch. For example, the AWJ can be trimming composites. There are still 2.3.3.1 Turning robotically scanned over the surface needs for improved fixturing and AWJ producing a scarfed geometry suitable tooling cutting heads and end effectors The turning of composite materials for repair as shown in Figure 15. to address a wider ranger of parts results in significant problems geometries and sizes. New software when using traditional turning and and offline programming have been grinding techniques due to the multi- 3. Conclusions critical to the acceptance of the AWJ directionality of the composite lay- systems in the aircraft industry.  up and its abrasiveness. OMCs are The AWJ process for composite typically not turned to produce parts, trimming has now become a but with the ability of the AWJ to mainstream process since it was first turn these materials, new designs may introduced in the 1980s. Advances

Page 18 WJTA on the web: www.wjta.org December 2008 Jet Edge’s 90,000 psi X-Stream Waterjet Pump Increases MEMBER Productivity Up To 50%

apable of producing pressures in excess of 90,000psi, C Jet Edge’s new 100hp X-Stream xP90-100 waterjet intensifier pump achieves much faster cutting speeds and drastically lowers operating costs compared to traditional 60,000psi pumps, enabling users to increase productivity and reduce part costs.

The X-Stream produces 50% more pressure than a 60,000psi waterjet intensifier pump, resulting in a 40-50% increase in productivity for many materials. The X-Stream supports a 75,000psi continuous operating pressure. Compared to a 60,000psi pump, typical operating pressures of 75,000psi use 30% less water, 30% less power, and up to 50% less abrasive, resulting in a 40% reduction in operating costs. They typically reduce taper by up to 0.001 inch. The X-Stream is capable of producing flow rates of 1.45gpm and supports up to a .017 inch orifice. Its fittings and tubing are rated for 100KSI. The X-Stream is backed by nearly 10 years of extensive research and development in hyper-pressure technology. Recommended Practices for Manually Operated High Pressure Waterjetting For more information about the Jet Edge X-Stream Equipment xP90-100 intensifier pump or other Jet Edge waterjet equipment, visit www.jetedge.com, email: sales@jetedge. WJTA offers the Recommended Practices for the com or call 1-800-JET-EDGE (538-3343). Use of High Pressure Waterjetting Equipment in English and Spanish. Topics include suggestions for personnel qualifications, operator training, and procedures for the proper operation of manually Yellow Lube operated high pressure waterjet equipment used by the construction, maintenance, repair, cleaning and A waterjet thread anti seize and thread lubricant that demolition industries. stays on the threads longer and will not stain your clothing or hands. The Recommended Practices Safety Video, available Proven in some of the in CD-ROM or VHS, is the companion video to the harshest Precision Recommended Practices for the Use of Manually Cutting and Portable Operated High Pressure Waterjetting Equipment. The Waterjet environ- video is a visual depiction of the major topics in the ments. Available in Recommended Practices. the larger 6 oz. tubes. To place an order, see the WJTA order form for Come see us at www.tsmoly.com publications/products on page 31 or contact the WJTA under waterjet products. office.

December 2008 WJTA on the web: www.wjta.org Page 19 Edmonton Waterjet Shop Experiences Nine Straight Years Of Growth, from page 7 definitely recommend Jet Edge to other businesses. He said his systems have been very reliable, are easy to maintain and hold their tolerances very well. He has the machines recalibrated only once a year.

“We are so happy,” Gerke said. “The ease of maintenance is excellent and the reliability of the machine is second to none.”

With its Jet Edge systems, G.O. H2O is capable of cutting virtually any material. In fact, they have cut just about everything, from NHL logos on pumpkins to 12-inch thick steel. The company utilizes dual cutting heads on about 70 percent of its projects to double productivity.

G.O. H2O’s most recognizable project can be seen at the Edmonton International Airport. Over the course of six months, the company cut 6,500 feet of interlocking mosaic tiles for 27 large swirl patterns that were installed in the airport corridors.

“No matter who you talk to, if they ask you what you have cut, you can say, ‘have you been to the airport?’ and they all have seen the mosaics,” Gerke said. “They do stand out.”

Gerke noted that one of his most satisfying accomplishments was in successfully performing a test cut G.O. H2O’s most recognizable project can be seen at the Edmonton International on .020-inch Pyrex® glass for a Airport. Over the course of six months, the company cut 6,500 square feet of technology company. The company interlocking mosaic tiles for 27 large swirl patterns that were installed in the asked him to cut tiny rectangular airport corridors. openings out of the 2x3-inch Pyrex® pieces. They sent three sample pieces inch, 12-inch-thick steel lifting lug by to 20 waterjet shops and G.O. H2O using a large nozzle and slowing the G.O. H2O also has considerable was the only shop that performed cut to 0.1-inch per minute. experience cutting 1x3-inch test a successful sample cut. G.O. H2O coupons of tough overlay materials got the project, and broke only three “The customer had done all the for the oil recovery industry, Gerke pieces out of 120. machining and they realized they noted. The coupons are typically steel needed to separate it,” Gerke recalled. In another notable project, G.O. “People said we couldn’t do it, but we H2O successfully separated a 30x48- did it. It was a feather in our cap.” (continued on page 22)

Page 20 WJTA on the web: www.wjta.org December 2008 StoneAge Introduces the Banshee BN33: WJTAListServ - A A New Tube Cleaning Nozzle Free Service To WJTA Members toneAge has announced another addition to the Banshee family of S The WJTAListServ enables tools – the Banshee BN33. The new you to take advantage of prompt Banshee is 33 mm in diameter and is email interaction with your capable of 20K psi and up to 50 gpm. colleagues. WJTAListServ is a The BN33 is suitable for tubes that are FREE email broadcast system 1-1/2 inches to 2 inches in diameter. developed by WJTA to help you communicate and network with The BN33 has a Universal other waterjet professionals. style head designed for polishing and unplugging tubes at the Participation is limited same time. As with all Banshee to WJTA members in good tools the BN33 requires no standing. You must sign up maintenance and is available For more information, visit www. in order to participate. To sign up for the WJTAListServ, with a variety of inlet connections; stoneagetools.com or contact contact Beth at the WJTA ½-inch NPT, 9/16 MP, and BSPP. StoneAge toll-free in the U.S. at office by email: [email protected], The Banshee BN33 is designed to (866)795-1586, phone: (970)259- phone: 314-241-1445, or fax: replace the Marten (MT-P8) and 2869, fax: (970)259-2868, or by email: 314-241-1449. Ferret (FT-P4) Tube Nozzles. [email protected].

WJTA Administration

Chairman of the Board President/Jet News Editor John Wolgamott George A. Savanick, Ph.D. (970)259-2869 (952)432-7594 Vice-President Treasurer Secretary Pat DeBusk Larry Loper Hugh B. Miller, Ph.D. (281)842-8000 (800)289-7447 (303)273-3558

2007-2009 Directors Bill Gaff Bill McClister (815)673-3835 (713)307-2142 Greg Galecki, Ph.D. Forrest Shook (573)341-4938 (248)624-5555 Mohamed Hashish, Ph.D. B.T. Steadman (253)850-3500 (601)933-4650 Paul Webster (281)925-4509

Emeritus Members Andrew F. Conn, Ph.D. Thomas J. Labus (410)532-3452 (262)245-9702 Thomas J. Kim, Ph.D. Fun-Den Wang, Ph.D. (401)874-5991 (303)279-9415

Association Managers

Mark S. Birenbaum, Ph.D. l Kenneth C. Carroll (314)241-1445

December 2008 WJTA on the web: www.wjta.org Page 21 Edmonton Waterjet Shop Jet Edge Selected To Participate In Experiences Nine Straight Years Of Minnesota’s Business Development Growth, from page 20 Mission To Israel that has been overlaid with a very hard material such as tungsten carbide or ceramic. et Edge International Sales Manager David J. Anderson J joined the Minnesota Trade Office’s Business “The tar sands are full of sand and abrasive and they Development Mission to Israel, Dec.11-18, 2008. Anderson are very hard on equipment so everyone and his dog is one of 30 business delegates who participated in the is trying to come up with a wear product to overlay on mission led by Minnesota Gov. Tim Pawlenty. The steel,” he said. “We do a lot of overlay samples. We delegation’s objectives are to acquire market information have to slow them down to 0.1-inch per minute and and business contacts, increase Minnesota exports to Israel, they are still difficult to cut.” facilitate high-tech exchanges and collaboration, and develop strategic relationships with key organizations that support One of Gerke’s proudest accomplishments has been U.S.-Israeli trade and investment. figuring out a way to efficiently recycle the abrasive material he uses in the majority of his jobs. Leave it to a As one of the world’s most prominent centers of innovation guy name Garnett to come up with an effective method and technology, Israel offers a wealth of opportunities for for reusing garnet. high-tech exchanges and collaboration. Additionally, with one of the best economic growth rates in the Middle East and “In our first two years [cutting 24/7], we had to shut an affinity for American products, Israel presents significant down every seven to ten days to clean out the tank,” market opportunities for Minnesota exporters. Gerke recalled. “We would be down 8 to12 hours. We had a sump truck come in and pump out the tank and haul the garnet off to the landfill. The first year, he charged $400 per visit. Two years later, it was three times the cost.”

After his second year in business, Gerke installed by PR Specialty Products, Inc. a WARDJet abrasive recycling system to reduce his downtime and counter rising landfill costs. He reclaims 50-70 percent of his garnet, and said the system paid for Specializing in custom lengths up to 96" itself within nine months. After he installed his second waterjet system, Gerke came up with an ingenious way to recycle garnet from both systems without having to buy a second recycler. He equipped the second table with a Jet Edge abrasive removal system with two side- loading dumpsters. After he fills one dumpster, it is 0%#)&&!##' ) (''"&(%& Material: +'%( replaced with an empty dumpster. The full dumpster is !"'$ &' then dumped into the recycler. This allows him to keep 0 #%(''"&! $%'&''*#(  #'%*&"'#' Colors:'#%  his new table up and running with no downtime. Once 0 #%(''" + !'% & Sizes: '"%&-" 1+1+ 1 a year, he cleans out the drops from both tanks. %'#"##%%('/(' 0!"'&"&"."' ,%(& "#& ) (&'#!&-&($'# 1%)   To keep a good cutting edge, Gerke mixes his used 0+&&) ,*#%"% "& , abrasive with new abrasive. He said has not noticed any %$ &!$ ,,"&%'""* slowdown in cutting speeds since he started recycling. Jet-Brick&'#" 0(&&$ & ''"! '&(%#% '!'% & For more information about G.O. H2O, visit www. goh2o.com, email [email protected] or call 1-877-43-GOH2O (434-6426). For more information Call or email us for a quote! about Jet Edge, visit www.jetedge.com, email sales@          jetedge.com or call 1-800-JET-EDGE (538-3343). 

Page 22 WJTA on the web: www.wjta.org December 2008 Barton Mines Announces Expanded Capacity At HPX™ Processing Plant

arton Mines Company has be used in demanding applications Barton offers eight grades of B announced the expanded capacity where other waterjet abrasives fall HPX™ waterjet abrasives. To learn of their HPX™ waterjet abrasive short. In addition, Barton HPX™ which HPX™ grade is best suited processing facility in North Creek, waterjet abrasives are the cleanest for a particular application or to New York. cutting media available. This order product samples, visit www. translates to less downtime due to barton.com, or contact Barton Mines The increased production is a clogged jets or erratic abrasive feed Company by email: [email protected] direct result of a comprehensive plant and a more cost-efficient operation. or call toll free: (800)741-7756. re-engineering and expansion that commenced in September 2007. “The additional volume comes at a time when demand for HPX has grown exponentially,” says R. Randolph Rapple, President.

Barton HPX™ high performance abrasives have a unique structure that produces sharp angular crystals. This unusual trait enables Barton HPX™ to outperform all other waterjet abrasives. The sharper, more angular edges make HPX™ the fastest cutting waterjet abrasive. Barton HPX™ produces a better edge quality and can

Guzzler Reintroduces Predator™ Liquid vacuum Tanker, from page 15 the American Society of Mechanical Engineers boiler code, the tank also complies with the U.S. Department of Transportation specification DOT412 for hauling hazardous materials on the highway.

“Industrial cleaning professionals look to Guzzler for unique solutions to their particular applications,” Lee said. “We are proud to reintroduce the Predator liquid vacuum tanker and are confident that our customers will appreciate our one-stop shop solution to address their industrial cleaning needs.”

For more information on the Predator liquid vacuum tanker from Guzzler Manufacturing, visit www. guzzler.com or call (800)627-3171. December 2008 WJTA on the web: www.wjta.org Page 23 Maxpro Technologies Expands Houston, Texas, Operation

axpro Technologies has M announced the expansion of Maxpro South, their Houston, Texas operation, into the states of Louisiana, Alabama and Mississippi.

This move will provide more direct support to the water blast industry in the region. Water blasting, oil and gas and other industries that use the Maximator line of high pressure valves, fittings and tubing will benefit from this increased technical support, sales and service.

Kim Guidry, located in Lafayette, Louisiana, has been appointed technical sales representative to head up this expansion. Guidry earned a B.S. degree in Industrial Technologies from the University of Southern Louisiana and brings over 20 years of experience in the high pressure industry. He can be contacted at (337)280-4223 or via email at kim@ maxprosouth.com.

Maxpro Technologies is the North American distributor of Maximator high pressure valves, fittings and tubing as well as air powered products including liquid pumps, gas boosters and air amplifiers. Maxpro also designs and manufactures various standard and custom pressure systems utilizing these Maximator products.

For more information visit us online at www.maxprotech.com, or call (814)474-9191.

The Jet News is published by the Wa- terJet Technology Association (WJTA) and is a benefit of membership in the Association.

©2008 Jet News. All rights reserved. Reproduction in any form forbidden without express permission.

Page 24 WJTA on the web: www.wjta.org December 2008 Notes From Another SUPER-WATER® User:

Special thanks to Renato Lombari for the following notes: I have worked with ultra-high pressure waterjets, operating up to 55,000 psi, for 19 years and SUPER-WATER® for 12 years. This includes: – plain water – plain water + SUPER-WATER® – plain water + abrasive – plain water + SUPER-WATER® + abrasive My work, during this time, gives an unambiguous demonstration of the economic advantages of using SUPER-WATER ® (1,2,3). Relative to plain water, the addition of SUPER-WATER® to an ultra-high pressure waterjet cutting system: – improves the quality of cut (6) (An excellent example of this enhanced quality was published by Weber [1997].) – increases cutting speeds by 30% to 200% (non-abrasive cutting system) – reduces intensifier operating and maintenance costs by 38% (non-abrasive cutting system) [from $11.12/hr (1993) to $6.86/hr (1996) = $4.26/hr reduction] These results were for cutting fiberglass acoustical panels using an intensifier. My results also parallel those previously published for precision cutting of natural-, synthetic-, silicone-, and foam-rubber (4) as well as synthetic materials such as Vistanex (5) and shoe soles (4). I have used SUPER-WATER® 100% of the time. Waste water and abrasive was disposed of without any problems. I have typically cut the following materials: – 304, 316 stainless steel – clear glass – marble and granite – duplex stainless steel – laminated glass – acrylic – aluminum (various alloys) – slate – ultra-high molecular weight polyethylene – titanium – blue tempered steel – , MDF and – brass (various alloys) – hot and cold rolled steel For a detailed analysis of abrasive cutting speeds and cut surface quality, please see the SUPER-WATER® groups file named “Reduction in Abrasive Consumption.doc” posted 04/21/2002. I have found that an approximate 0.1% to 0.2% SUPER-WATER® solution produces the following three-fold effects: – Reduces flow resistance due to substantial drag reduction. Hoyt (1986) produced laboratory turbulent rheometer findings showing that even 9 ppm resulted in a 20% drag reduction and Cobb and Zublin (1985) obtained a drag reduction of 54% in 2187 meters of 2.16 cm (0.85 inch) id coiled tubing. – Collimates the jet leaving the nozzle – Introduces macromolecular bombardment (Kudin et al., 1973) of polymer molecules dissolved in the water

REFERENCES 1. R. Lombari, “Ultra-High Pressure Non-Abrasive Polymer Jetting: A Production Environment Implementation,” Proceedings of the 9th American Waterjet Conference (Dearborn, Michigan: August 23-26, 1997), Paper 17, pp. 251-266. 2. R. Lombari, “Cutting Fiberglass Acoustical Panels,” Jet News, December 1995, p. 7. 3. R. Lombari, Letter to the Editor, ... “the longevity of our consumable jet components due to the lubricity of SUPER-WATER®,” Jet News, November 1996, pp. 2 and 11. 4. W.G. Howells, “Polymerblasting with SUPER-WATER® from 1974-1989: a Review,” International Journal of Water Jet Technology, Volume 1, Number 1, (March 1990), pp. 1-16. 5. W.G. Howells, “Additive Improves Abrasive Jet Cutting,” Jet News, December 1995, pp. 5 and 10. 6. D. Weber, Letter to the Editor, Jet News, February 1997, p. 12.

For more information and references, visit www.berkeleychemical.com, email: [email protected], or contact W. Glenn Howells, Ph.D., President, Berkeley Chemical Research, Inc., Tel: 510-526-6272, Fax: 510-525-2375, Mail: PO Box 9264, Berkeley, CA 94709-0264.

-ADVERTISEMENT- StoneAge Upgrades the 40K psi Barracuda Cartridge

toneAge is offering an upgraded cartridge assembly that will retrofit Sinto existing 40K psi Barracuda, Gopher, and SL tools and is being supplied with all new tools as of November 20, 2008. This upgrade is designed to increase the operational life of the high pressure seals.

The following diagrams illustrate how StoneAge is replacing the BC 405 Cartridge Assembly with the new BC 505 Cartridge Assembly. Several of the items have changed.

These BC 505 Cartridge Assemblies became available on November 20, 2008. If you have existing stock of the old cartridge assemblies or the individual parts, StoneAge will accept those unused items for credit return. Visit www. stoneagetools.com to download or print these drawings.

StoneAge is continually working to create new products and improve existing products, and welcomes your feedback about this upgrade and your success with this product improvement. Contact StoneAge toll-free in the U.S. at (866)795-1586, phone: (970)259-2869, fax: (970)259-2868, or by email: sales@ stoneagetools.com.

Page 26 WJTA on the web: www.wjta.org December 2008 WJTA Welcomes New Members

Pedro Hans Dominguez Stefano Roti Eric Bieberich Corporate TNT High Pressure Pratissoli Pompe Fort Wayne Wire Die, Inc. Waterworks, Ltd. Via Enrico Fermi 25 2424 American Way Stewart R. Browne 9451 49th Street S. Ilario d’ Enza Fort Wayne, IN 46809-3005 Manufacturing Co. Inc. Edmonton, AB T6B 2L8 Reggio Emilia 42049 Phone: (260)747-1681 Canada Italy Fax: (260)747-4269 Alan R. Browne Phone: (780)469-4073 Phone: [39](522)904311 James Browne Fax: (780)463-2077 Fax: [39](522)904444 Frank Blaine 1165 Hightower Trail Kitchell Environmental Services Atlanta, GA 30350 Rex Foster Arnie Salinas 1707 E Highland Avenue Phone: (770)993-9600 Prepcon, Inc. GMA Garnet (USA) Corporation Phoenix, AZ 85016-4640 Fax: (770)594-7758 6737 Dogwood Road 480 N. Sam Houston Pkwy E Phone: (602)222-5300 Baltimore, MD 21207-4121 Suite 130 Fax: (602)264-9296 IMS Maintenance Services Phone: (410)265-6722 Houston, TX 77060-4108 Maurice Duguay, Jr. Fax: (443)200-1010 Phone: (832)243-9300 Allan Cox Fax: (832)243-9301 P.O. Box 6 Atlantic Industrial Cleaners Chris Kay Timmins, ON P4N 7C5 11 Brown Avenue Tom Canada Super Products LLC Dartmouth, NS B3B1Z7 Phone: (705)235-9274 17000 W. Cleveland Avenue KMT Aqua-Dyne, L.P. Canada Fax: (705)235-8989 New Berlin, WI 53151-3593 3620 West 11th Street Phone: (902)468-9011 Phone: (262)784-7100 Houston, TX 77008-6004 Fax: (902)468-5977 Moe Duguay, Sr. Fax: (262)784-9561 Phone: (713)864-6929 979 Goldmine Road Fax: (713)864-0313 Rob Haviland Timmins, ON P4N 7C5 Greg Loraine Crowe Manufacturing Canada DYNAFLOW, Inc. Rene Stuehlinger 216 S. Torrence Street Phone: (705)264-1642 10621-J Iron Bridge Road BHDT GmbH Dayton, OH 45403-2625 Fax: (705)235-8989 Jessup, MD 20794-9381 Werk-VI-Strasse 52 Phone: (937)254-4441 Phone: (301)604-3688 Kapfenberg A-8605 Trevor Niemi Fax: (937)254-4475 Fax: (301)604-3689 Austria Timmins Jacobile Wash Phone: [43](3862)303-315 24 Hollnor Road Ignacio Lastiri Fax: [43](3862)303-304 Porcupine, ON P0N 1C0 Jonathan Lukas Vialven SA Canada HydroChem Industrial Mirave 2742 Services, Inc. Ulrich Thomas, Ph.D. Buenos Aires C1281ABB Keith Huber, Inc. 900 Georgia Avenue Aqua Drill International Argentina Alan Klaser Deer Park, TX 77636-2518 1300 FM 646 East Phone: [54](11)4303-3415 Phone: (713)393-5624 Dickinson, TX 77539-3022 Fax: [54](11)4303-3417 14220 Highway 49 North Fax: (713)393-5959 Phone: (281)337-0900 Gulfport, MS 39503 Fax: (281)337-7270 Henry Yang Phone: (228)832-0992 Iris Montemayor Fax: (228)832-2068 Semlima Industrial Nuova Fima, USA Matthew Verghese Company, Ltd. Kroy Industries, Inc. 15255 Gulf Freeway Hydrolink FZE 19, 36th Road Suite 148D Jebel Ali- Headquarters David D. Le Duc Taichung Industrial Park Houston, TX 77034-5351 PO Box 18502 Taichung 40700 Phillip Seever Phone: (281)464-0500 Dubai Taiwan, Republic of China 522 W. 26th Street Fax: (281)464-0506 United Arab Emirates Phone: [886](4)23550190 P.O. Box 309 Phone: [971](4)8861414 Fax: [886](4)23550196 York, NE 68467 Alfredo Sanchez Oviedo Fax: [971](4)8861413 Phone: (402)362-6651 Representaciones Industriales Fax: (402)366-6566 JBL S.A. de C.V. Gomez Farias #1957 Albert Reyna Individuals Best wishes for a 5223 89th Street Col: Flores Magon Lubbock, TX 79424 Veracruz, Ver. 91900 Happy, Healthy Phone: (806)798-2015 Mexico Marcos Requena Arcajo Phone: [52](229)932-5672 Fax: (806)798-2018 Ingenieria Y Plantas Fax: [52](229)932-6278 and Safe New De Proceso S.L. Parque Empresarial Principado Brian Ritchie De Asturias Avda. del Zinc s/n Year from the Corporate Alternates Denholm Oilfield Primero - Oficina nº2 Services UK, Ltd. Avilés, Asturias 33400 WJTA Officers, Stephen Davis Greenbank Place Spain East Tullos Industrial Est. KMT Aqua-Dyne, L.P. Phone: [34](98)5514476 Abedeen, Scotland AB12 3BT Board of 3620 West 11th Street Fax: [34](98)5514477 United Kingdom Houston, TX 77008-6004 Phone: [44](1224)248600 Directors & Staff Phone: (713)864-6929 Fax: [44](1224)248032 Fax: (713)864-0313

December 2008 WJTA on the web: www.wjta.org Page 27 Jet Edge Introduces Easy-to-Use CAD/CAM Nesting Software For Waterjet Cutting

et Edge is now offering the path generation, and NC code are capable of producing pressures J easy-to-learn and use SigmaNEST generation. With it, waterjet operators from 30,000psi to 90,000psi. They Companion™ CAD/CAM nesting can load DXF files to automatically are available in electric and diesel software on its precision waterjet or manually nest parts. They also can models ranging from 30hp to 280hp. cutting systems. create new tasks using standard shapes Jet Edge’s open-architecture motion available in the program’s library. controllers are compatible with most Developed by SigmaTEK Systems, Companion also allows operators to CAD/CAM software, including LLC, of Cincinnati, SigmaNEST edit part parameters and generate a SigmaNEST and SigmaNEST Companion uses a wizard-based variety of custom reports, including Companion. approach to allow waterjet operators cost, layout and summary reports. with little or no CAD/CAM For more information, visit www. experience to design, edit and nest Jet Edge manufactures a full line of jetedge.com, call (800)JET-EDGE parts quickly with little training. precision waterjet cutting machines, (538-3343) or email sales@jetedge. Available at a fraction of the cost intensifier pumps and waterjet parts. com. For more information about of the full SigmaNEST program, Jet Edge waterjet tables are available SigmaNEST, visit www.sigmanest. Companion features numerous in a wide range of sizes, from 30 com, call (513)674-0005 or email SigmaNEST functions­ such as DXF inchesx30 inches to 30 feetx100 feet. [email protected]. import, TrueShape nesting, automatic Jet Edge waterjet intensifier pumps

Page 28 WJTA on the web: www.wjta.org December 2008 2009 American WJTA Conference And Expo August 18-20, 2009 Marriott Houston Westchase Hotel  Houston, Texas, USA

Announcement and Call for Papers

Impressive progress and a fast-growing understanding of the diversified applications of waterjet technology are generating a growing excitement in the industry. New techniques and applications are being developed and current ones are being improved. Waterjet technology, now being used in nearly all types of industry — manufacturing, mining, construction, concrete, stone, aerospace, engineering, oil and gas, power plants, process, and medical industries — continues to expand at a rapid pace.

The 2009 American WJTA Conference And Expo will focus, from a practical and scientific viewpoint, on the most up-to-date advances in waterjetting equipment, techniques, and applications. The areas to be addressed include, but are not limited to:

 Abrasives, Water, and the Environment  Hydrodemolition  Advanced Industrial Applications  Hydroexcavation  Advances In High Pressure Technology and Equipment  Jet Mechanics and Visualization  Automotive and Aerospace Applications  Jet-Material Interaction  Cleaning and Coating Removal  Manufacturing Processes  Components and Systems  Market and Future Needs  Construction and Non-Manufacturing Applications  Novel Jets and Applications  Process Modeling and Control Studies  Contractor Applications and Processes  Rock Cutting  Demilitarization, including Removal of Land Mines (Demining)  Safety, Training, and Environmental Protection  Drilling Applications  Vacuum Equipment  Excavation, Tunneling, and Mining Applications

Commercial and academic authors are encouraged to submit titles and abstracts for consideration. To submit an abstract(s), please complete the abstract submission form on the back of this sheet, attach a copy of your abstract(s), and forward to the attention of the Conference Coordinator at the WaterJet Technology Association. An electronic submission form can be found on the WJTA web site at www.wjta.org. The deadline date for submission of abstracts is January 15, 2009. An Abstract Review Committee consisting of five referees will review the abstracts. Authors will be advised byFebruary 27, 2009, regarding the decision of the Abstract Review Committee. The 2009 American WJTA Conference And Expo is organized by the WaterJet Technology Association. The WaterJet Technology Association looks forward to providing this forum and to your involvement and participation.

2009 WJTA Conference Commit- Authors - Please Note tee  Papers must be original. Papers must not have been published elsewhere or be pending Pat DeBusk publication. Co-Chairman  Publication Fee. A nonrefundable publication fee (equal to the price of a member Full DeBusk Industrial Services Company Conference registration) is required. This publication fee will be waived if at least Bill McClister one author registers (Full or Combo) for the WJTA Conference. (Authors must Co-Chairman pay the applicable member or nonmember price.) Also, one registration is good for Veolia Environmental Services multiple papers. The deadline date for receipt of your final paper will beMay 4, 2009. Mohamed Hashish, Ph.D. The publication fee or payment for a Full or Combo registration is due no later than Editor June 15, 2009. Your paper will not be included in the Proceedings if the publication fee Flow International Corporation or registration fee is not paid by this date. Bill Gaff  Papers and presentations must be in English. Papers should be no longer than 15 printed Jetstream of Houston, LLP pages. A “Paper Guide” containing directions for submitting papers will be forwarded to you after your abstract is accepted. Papers that do not follow the “Guide” will be returned Hugh B. Miller, Ph.D. to the author(s) for correction(s) or charged a fee for revisions made by the WaterJet Colorado School of Mines Technology Association office. Gary Noto Veolia Environmental Services  Papers should be free of commercialism. B.T. Steadman  Papers should be submitted as a Word file and a PDF file. Vacuum Truck Rentals, LLC 2009 American WJTA Conference And Expo August 18*-20, 2009  Marriott Houston Westchase Hotel  Houston, Texas

Abstract Submission Form For each paper to be submitted for consideration, please complete this form, attach a copy of the abstract, and mail or fax to WJTA by January 15, 2009. An electronic submission form can be found on the WJTA web site at www.wjta.org. Authors will be advised by Febru- ary 27, 2009, regarding the decision of the Abstract Review Committee.

Paper Information Paper Title ______Authors ______Contact Person (Please print or type) Name ______(First Name) (Surname/Family Name) Position/Title ______Company/Organization ______Street Address ______City, Province ______State ______Country______Zip/Postal Code ______Business Telephone ______Fax ______Email ______Web site ______Signature ______Date ______

Please check the category that best describes the general nature of your paper.  Applications  Research

Key words (Check the boxes under the different categories that apply to your paper):

Type of Study Process Related Industry  Modeling  Cutting  Generic  Experimental study  Drilling  Shipyard  Hardware development  Surface preparation  Mining  Contractor case study  Cleaning  Construction  Manufacturing case study  Stripping  Aerospace/Aircraft  Software development  Safety  Automotive  Economic analysis  Milling  Oil/Gas/Refinery  Legal and Safety  Jet-assisted  Quarrying  Other ______ Other ______ Other ______

Jets Material Environment  Waterjet  Metal  Field work  Abrasive-waterjet  Rock  Factory work  Abrasive suspension jet  Glass  Submerged  Pulsed  Ceramic  Nuclear  Cavitation  Composite  Demilitarization  Polymer Jets  Concrete  Offshore  Other ______ Other ______ Other ______

*August 18 is reserved for the short course(s). Mail completed form and abstract, NO LATER THAN JANUARY 15, 2009, to: Conference Coordinator, 2009 WJTA American Waterjet Conference, WaterJet Technology Association, 906 Olive Street, Suite 1200, St. Louis, MO 63101-1448, USA, telephone: (314)241-1445, fax: (314)241-1449, email: [email protected], web site: www.wjta.org WaterJet Technology Association's Order Form for Publications/Products 10-08

THREE EASY Name ______Member # ______Payment Method WAYS TO ORDER Company ______‰ Check or Money Order payable to WJTA By Phone: Just call Address ______(U.S. DOLLARS ONLY) (314)241-1445 and have your credit card information City ______State ______‰ PO # ______(Enclose PO) ready. (MC/VISA/AMEX/ Discover ONLY). Country ______Postal Code ______‰ Please charge my ‰ MC ‰ VISA ‰ AMEX ‰ Discover By Fax: Fill out the order Phone # [ ]( ) ______Fax # [ ]( )______Credit form with your credit card information and call our 24- Card # ______Email______hour fax number at: (to receive shipping confirmation) Exp. Date______(314)241-1449. Billing Address (if different from above): By Mail: Fill out the order ______form and mail with Address ______Print name as it appears on card applicable payment to: WJTA, 906 Olive Street, City ______State ______Ste. 1200, St. Louis, MO Country ______Postal Code ______Cardholder's signature 63101-1448.

WJTA Non Member Shipping & Member Price Price Handling ____ Proceedings CD-ROM of The 2007 American WJTA Conference And Expo @ $ 109.00 $ 129.00 $ 8.00 = $______Proceedings CD-ROM of The 2005 WJTA American Waterjet Conference @ $ 35.00 $ 55.00 $ 8.00 = $______Proceedings CD-ROM of The 2003 WJTA American Waterjet Conference @ $ 35.00 $ 55.00 $ 8.00 = $______Proceedings CD-ROM of The 2001 WJTA American Waterjet Conference @ $ 10.00 $ 30.00 $ 8.00 = $______An Overview of Waterjet Fundamentals And Applications, Fifth Edition (2001) @ $ 55.00 $ 70.00 $ 8.00 = $______An Overview of Waterjet Fundamentals And Applications @ $ 30.00 $ 35.00 $ 8.00 = $______(8/17/03 PowerPoint presentations in printed format) ____ Waterjet Technology: Basics and Beyond (8/19/07 PowerPoint presentations in printed format) @ $ 20.00 $ 25.00 $ 8.00 = $______Waterjet Technology: Basics and Beyond (8/21/05 PowerPoint presentations in printed format) @ $ 20.00 $ 25.00 $ 8.00 = $______Minimum charge of $8 per order. $8 for 1-3 items purchased; $16 for 4-7 items purchased; for 8 or more items purchased, contact the WJTA office.

‰ Waterjet Equipment Recommended Safety Practices. Specify: ‰ English Edition or ‰ Spanish Edition ‰ Vacuum Equipment Recommended Safety Practices. Specify: ‰ English Edition or ‰ Spanish Edition

1 - 10 copies _____ # of copies x $ 7.00 ea. $ 12.00 ea. = $______11 - 99 copies _____ # of copies x $ 6.00 ea. $ 10.00 ea. = $______100 - or more copies _____ # of copies x $ 5.00 ea. $ 8.00 ea. = $______Shipping & Handling of Recommended Safety Practices 1-10 copies .... $0.50 per book, 11-99 copies ...... $0.40 per book, 100 - or more copies .. $0.25 per book ____ # of copies x $______= $______

‰ Waterjet Equipment Recommended Safety Practices Video. Specify: ‰ VHS Video or ‰ CDROM ‰ Vacuum Equipment Recommended Safety Practices Video. Specify: ‰ VHS Video or ‰ CDROM 1 - 4 copies _____ # of copies x $ 49.95 ea. $ 99.95 ea. $ 6.00* = $______5 - 10 copies _____ # of copies x $ 39.95 ea. $ 89.95 ea. = $______11 - or more copies _____ # of copies x $ 29.95 ea. $ 79.95 ea. = $______Shipping & Handling of Safety Video ...... = $______*Contact the WJTA office for the shipping & handling charge of more than one Safety Video.

Baseball Cap _____ # of caps x $ 7.95 ea. $ 7.95 ea. $ 6.00 ea. = $______WJTA Decals. Minimum $5 order includes shipping and handling. 5” decals 4 for $5, additional decals .50 each _____ # of decals = $______3.5” decals 6 for $5, additional decals .45 each _____ # of decals = $______2” decals 8 for $5, additional decals .40 each _____ # of decals = $______WJTA Executive Organizer _____ # of organizers x $ 20.00 ea. $ 30.00 ea. $ 8.00 ea. = $______WJTA Navy Blue Polo Shirt Size _____ (S, M, L, XL, 2X) _____ # of shirts x $ 30.00 ea. $ 35.00 ea. $ 7.00 ea. = $______

Waterjet Safety Cards. Specify: ‰ English ‰ Spanish 1-10 safety cards _____ # of cards x .30 each .50 each = $______11-99 safety cards _____ # of cards x .25 each .45 each = $______100-249 safety cards _____ # of cards x .20 each .40 each = $______250+ safety cards _____ # of cards x .17 each .35 each = $______Shipping & Handling of Safety Cards: 1-50 cards FREE (For the purchase of more than 50, call the WJTA office for the shipping & handling charge.) = $______

For shipping and handling charges outside the USA, contact the WJTA Office. TOTAL ENCLOSED $